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<p>The ultrasonic surface rolling process (USRP) is a chip-free, thermally inert technique that enhances material surfaces by inducing plastic deformation, grain refinement, and residual compressive stress. While conventional ultrasonic rolling devices (CURD) are typically single-sided, their application to slender shafts-due to low structural stiffness-often results in uneven pressure distribution and reduced surface uniformity. To address these limitations, this study proposes a novel slender shaft ultrasonic rolling device (SSURD) designed for dual-sided, stable processing. Experimental results demonstrate that SSURD significantly improves surface properties: for SET1 samples, surface roughness decreased by 91.8 % and microhardness increased to 529.7 HV, in addition, compared with CURD, SSURD can effectively reduce the bending deformation of slender shafts, making the surface morphology along the axial direction more uniform and consistent. For SET2 samples, the surface roughness decreased from 1.125 µm to 0.048 µm. The surface hardness increased from approximately 55 HRC before ultrasonic rolling to about 61 HRC after processing; Fatigue fracture occurred under CURD treatment but was avoided with SSURD, indicating enhanced fatigue resistance. These findings confirm the SSURD’s advantages in enhancing surface integrity and reliability for slender shaft components.</p>

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Finishing and strengthening effects in rolling of slender shafts with a new designed ultrasonic vibration rolling device

  • 期刊论文

  • 发表日期：

    2026年4月13日

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  • Meng Zhao,
  • Yan Xia,
  • Guosheng Su,
  • Hongxia Zhang,
  • Yujing Sun,
  • Binxun Li,
  • Peirong Zhang,
  • Jin Du,
  • Bin Fang,
  • Gaofeng Wei,
  • Chonghai Xu

摘要

The ultrasonic surface rolling process (USRP) is a chip-free, thermally inert technique that enhances material surfaces by inducing plastic deformation, grain refinement, and residual compressive stress. While conventional ultrasonic rolling devices (CURD) are typically single-sided, their application to slender shafts-due to low structural stiffness-often results in uneven pressure distribution and reduced surface uniformity. To address these limitations, this study proposes a novel slender shaft ultrasonic rolling device (SSURD) designed for dual-sided, stable processing. Experimental results demonstrate that SSURD significantly improves surface properties: for SET1 samples, surface roughness decreased by 91.8 % and microhardness increased to 529.7 HV, in addition, compared with CURD, SSURD can effectively reduce the bending deformation of slender shafts, making the surface morphology along the axial direction more uniform and consistent. For SET2 samples, the surface roughness decreased from 1.125 µm to 0.048 µm. The surface hardness increased from approximately 55 HRC before ultrasonic rolling to about 61 HRC after processing; Fatigue fracture occurred under CURD treatment but was avoided with SSURD, indicating enhanced fatigue resistance. These findings confirm the SSURD’s advantages in enhancing surface integrity and reliability for slender shaft components.